Mailable content carrier device

ABSTRACT

A mailable content carrier device incorporates content therein during its construction. Automated processing need only place content appropriately during construction with subsequent construction steps enclosing the content. The result is a mailable content carrier constructed by high-speed automation including location of content therein.

BACKGROUND OF THE INVENTION

[0001] Bulk mailing devices range from simple postcards to elaborate and ornate packages drawing the recipient's attention to the package or package content. In many cases, a bulk mailing device serves as a carrier, i.e., holds content for delivery. Popular examples of bulk mailing content include CDs, seed packages, perfume, shampoo, soap, telephone calling cards. Such content is generally flat in overall shape. A variety of bulk mailing devices have evolved around the promotional or mass mailing industry.

[0002] In every case, however, bulk mailing packages must be “mailable.” In other words, each package together with its content must arrive intact at the intended destination without damage or loss of contents. A bulk mailing carrier device must be adapted for automation in routing and delivery handling without risk if damage or loss of content. In other words, it must be adapted for processing and delivery by machinery of a mail carrier service, e.g. processed by the machinery of the US Postal Service. It will be understood, therefore, that a bulk mailing carrier device must insure against loss of content, i.e., must adequately enclose and secure the content carried thereby.

[0003] Furthermore, automation plays vital role in preparation of a bulk mailing device for submission to a mail carrier service. Typically, such bulk mailing devices begin as a “blank” planar paper structure fed into automated folding and addressing machinery. The output of such automation is a massive inventory of addressed material sorted and ready for submission to a mail carrier service, i.e., ready for submission to the US Postal Service. Any processing not automated, i.e., any individual hand manipulation, slows processing to an unacceptable speed. Thus, high-speed automation from paper blank to a sorted and addressed mailable item is essential. For bulk mailing carrier devices, e.g., carrying content such as CDs, seed packages, and the like, the automated process must also locate the content in the bulk mailing device. In other words, hand placement of content is not feasible under modern bulk mailing automation.

[0004] Thus, to be effective, such bulk mail processing machinery, i.e., machinery preparing bulk mailing material for submission to a mail carrier service, necessarily operates automatically and at high speed. While actual production speed varies depending on the machinery used and on the nature of the mailable device and the content carried thereby, the speed required is much, much greater than anything possible by hand manipulation of the blank or by hand insertion of content into the bulk mailing device. Bulk mailing is simply not competitive without adaptation to high-speed processing in preparation of the bulk mailing device for submission to a mail carrier service. Speed is an inherent advantage in any enterprise preparing bulk material for submission to a mail carrier service. When incorporating a carrier function, i.e., delivering content, high-speed production slows due to the complexity of locating the content within the bulk mailing device.

[0005] It would be desirable to provide a mailable content carrier device adapted for high-speed automation in constructing the device and in locating content within the device preparatory to its submission to a mail carrier service. The subject matter of the present invention provides such a mailable content carrier device prepared for submission to a mail carrier service fully by high-speed automation.

SUMMARY OF THE INVENTION

[0006] The subject matter of the present invention contemplates a mailable content carrier device capable of incorporating content therein during its construction. As a result, automated processing need only place content appropriately during construction with subsequent construction steps enclosing the content. The result is a mailable content carrier constructed by high-speed automation including location of content therein.

[0007] The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation of the invention, together with further advantages and objects thereof, may best be understood by reference to the following description taken with the accompanying drawings wherein like reference characters refer to like elements.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] For a better understanding of the invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:

[0009]FIG. 1 illustrates in perspective a mailable content carrier device according to a preferred embodiment of the present invention ready for submission to a mail carrier service.

[0010]FIG. 2 illustrates in plan view a blank form the device of FIG. 1 prior to automated high-speed manipulation thereof to form the device as illustrated in FIG. 1 and prior to placement of content therein.

[0011]FIG. 3 illustrates in perspective the blank of FIG. 2. prior to entry into automated folding and content placement equipment.

[0012]FIG. 4 illustrates preliminary steps during high-speed automated folding of the blank of FIG. 2 to construct the mailable content carrier device of FIG. 1.

[0013]FIG. 5 illustrates high-speed automated placement of content in the partially folded blank of FIGS. 2-4 during automated high-speed construction thereof.

[0014]FIG. 6. illustrates high-speed automated folding steps subsequent to placement of content in construction of the device of FIG. 1.

[0015]FIG. 7 illustrates a final high-speed folding step completing construction of the device of FIG. 1 by automation including automated placement of content therein.

[0016]FIG. 8 illustrates the mailable content carrier device of FIG. 1 during deployment of content by a recipient.

[0017] FIGS. 8 illustrates deployment of content within the mailable content carrier device of FIG. 1 by an end user, i.e., addressee or recipient, thereof.

[0018]FIG. 9 illustrates the mailable content carrier device of FIG. 8 as taken along lines 9-9 of FIG. 8.

[0019]FIG. 10 illustrates an overall bulk mailing operation including processing an inventory of the blanks of FIG. 2 and content carried thereby into the mailable content carrier devices of FIG. 1 for submission to a mail carrier service and ultimately distribution to individual members of a population of end users.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0020]FIG. 1 illustrates a preferred embodiment of the present invention, a mailable content carrier device 10. Device 10 assumes a generally flat overall shape and is suitable for mailing by way of a mail carrier service by suitable address indicia and postage thereon.

[0021] Device 10 serves as a carrier of content held therein. As used herein, the term “content” shall referred to any generally flat body of such shape and size in relation to that of device 10 so as to maintain device 10 in a generally flat overall shape suitable for mailing and while holding such content therein. In other words, without significantly deforming device 10 and thereby degrading its qualification as a flat mailable item. Typical content includes, but need not be limited to, CDs, seed packages, perfume packages, credit cards, telephone calling cards, bank cards, or any of the broad variety of content often included in bulk mailings, advertising mailings, or mass distribution mailings to pre-exiting customers. While most applicable to bulk or mass mailing, the present invention is not limited to such applications.

[0022] The present invention does find particularly useful application, however, where high-speed automated preparation and content placement are desirable such as in bulk or mass mailing operations preliminary to submission of material to a mail carrier service, e.g. preliminary to submission to the US Postal Service or other national or private mail carrier services. It will be understood, however, that the device of the present invention may be processed or constructed by hand and find utility as a mailable content carrier device.

[0023]FIG. 2 illustrates device 10 as a blank 10′ ready for introduction into automated high-speed folding and content placement equipment (not shown). Blank 10′ includes in series a tongue panel 12, a first outer panel 14, a center panel 16, a second outer panel 18, and a content site panel 20. Tongue panel 12 is contiguous with first outer panel 14 along a lateral fold line 30. Content site panel 20 is contiguous with second outer panel 18 along a lateral fold line 32. Each of fold lines 30 and 32 occupy the full lateral dimension of blank 10′. As will be described more fully hereafter, tongue panel 12 folds over along line 30 into face-to-face relation with first outer panel 14 leaving tongue panel 12 within, i.e., as an internal structure of, the finished device 10. Similarly, content site panel 20 folds over along line 32 into face-to-face relation with second outer panel 18 leaving content site panel 20 within, i.e., as an internal structure of, the finished device 10.

[0024] First outer panel 14 and second outer panel 18 are contiguous along lateral fold line 34 and lateral fold line 36. Each of fold lines 34 and 36 extend only partially inward from the outer longitudinal edges, i.e., those edges parallel to longitudinal axis 40, of panels 14 and 18. More particularly, each of lines 34 and 36 extend laterally inward toward and terminate at respective ends of center panel 16. Thus, center panel 16 and fold lines 34 and 36 are coincident to a central lateral axis 42 of blank 10′. As will be explained more fully hereafter, panels 14 and 18 fold together along lines 34 and 36, respectively, and come into face-to-face relation with panels 12 and 20, respectively, as captured therebetween in the finished mailable content carrier device 10.

[0025] Center panel 16 is removably attached to panels 14 and 18, e.g., along a perforated cut line 38 surrounding center panel 16. Center panel 16 remains in place, i.e., coupled to panels 14 and 18, during construction and transit of device 10. Center panel 16 thereby restrains content within device 10 during transit. As will be explained more fully hereafter, center panel 16 detaches in response to deployment of content, i.e., when the recipient of device removes content from device 10. Removal of center panel 16 leaves an exit or portal for content urged against the inner surface of center panel 16. In other words, content or other internal structures within mailable content carrier device 10 bears against the inner surface of center panel 16 thereby detaching center panel 16 along cut line 38 and leaving an opening in device 10 for removing content. During transit to the end user, i.e., as mailed, center panel 16 remains attached and serves to secure and complete enclosure of content within mailable content carrier device 10.

[0026] First outer panel 14 is bifurcated into sub-panel 14 a and sub-panel 14 b. In the preferred embodiment, sub-panels 14 a and 14 b are contiguous along partial lateral fold lines 50 a and 50 b. Fold lines 50 a and 50 b are co-linear and each extends partially inward from the outer longitudinal edges of blank 10′, i.e., fall short of the other one of fold lines 50 a and 50 b. In an alternative embodiment of the present invention, fold lines 50 a and 50 b extend fully inward to form a single fold line 50 separating sub-panels 14 a and 14 b. In the preferred embodiment, however, a curvilinear perforated cut line 52 joins fold lines 50 a and 50 b across panel 14. In the particular embodiment illustrated, cut line 52 assumes a generally semi-circular path. It will be understood, however, that cut line 52 may follow any arbitrary path connecting lines 50 a and 50 b. Thus, fold lines 50 a and 50 b together with cut line 52 define a boundary between sub-panels 14 a and 14 b. As explained more fully hereafter, upon deployment of content, panel 14 folds along lines 50 a and 50 b and sub-panels 14 a and 14 b separate along perforated cut line 52 but remain attached along fold lines 50 a and 50 b.

[0027] Similarly, second outer panel 18 is bifurcated into sub-panel 18 a and sub-panel 18 b. In the preferred embodiment, sub-panels 18 a and 18 b are contiguous along partial lateral fold lines 60 a and 60 b. Fold lines 60 a and 60 b are co-linear and each extends partially inward from the outer longitudinal edges of blank 10′, i.e., falls short of the other one of fold lines 60 a and 60 b. In an alternative embodiment of the present invention, lines 60 a and 60 b extend fully inward to form a single fold line 60 separating sub-panels 18 a and 18 b. In the preferred embodiment, however, a curvilinear perforated cut line 62 joins fold lines 60 a and 60 b across panel 18. In the particular embodiment illustrated, cut line 62 assumes a generally semi-circular path. It will be understood, however, that cut line 62 may follow any arbitrary path connecting lines 60 a and 60 b. Thus, fold lines 60 a and 60 b together with cut line 62 define a boundary between sub-panels 18 a and 18 b. As explained more fully hereafter, upon deployment of content, panel 18 folds along lines 60 a and 60 b and sub-panels 18 a and 18 b separate along perforated cut line 62 but remain attached along fold lines 60 a and 60 b.

[0028] Tongue panel 12 includes length portions 12 a, 12 b, and 12 c. The lateral dimension, i.e., that dimension parallel to axis 42, of length portion 12 a corresponds to the lateral dimension of center panel 16. More particularly, the lateral dimension of portion 12 a is slightly smaller than that of center panel 16 whereupon removal of center panel 16 the length portion 12 a of panel 12 protrudes through the opening left by removal of center panel 16. Length portion 12 b of panel 12 corresponds in lateral dimension to that of panels 14 and 18. Length portion 12 c is intermediate portion 12 a and 12 b and varies, i.e. makes transition, in lateral dimension from that of portion 12 a to that of portion 12 b.

[0029] Content site panel 20 is generally similar in shape and dimensions to that of tongue panel 12. Content site panel 20 includes length portions 20 a, 20 b, and 20 c. The lateral dimension, i.e., parallel to axis 42, of length portion 20 a corresponds to the lateral dimension of center panel 16. More particularly, the lateral dimension of portion 20 a is slightly smaller than that of center panel 16 whereupon removal of center panel 16 length portion 20 a of panel 20 may protrude through the opening left by removal of center panel 16. Length portion 20 b of panel 20 corresponds in lateral dimension to that of panels 14 and 18. Length portion 20 c lies intermediate portions 20 a and 20 b and varies, i.e., makes transition, in lateral dimension from that of portion 20 a to that of portion 20 b.

[0030] Blank 10′ further includes tab panels 70 and 72 adjoining panel 20 at longitudinal fold lines 74 and 76, respectively, along length portion 20 a thereof. In contrast to other fold lines of blank 10′, fold lines 74 and 76 lie parallel to longitudinal axis 40. This configuration allows automated placement of content on an upward-facing surface of content site panel 20 and during construction of device 10. With content so placed on panel 20, tab panels 70 and 72 fold over along lines 74 and 76, respectively, to capture content in place on content site panel 20. In this configuration, i.e., with content resting on panel 20 and tab panels 72 and 74 folded over and capturing the content thereat, panels 12 and 20 may fold over along lines 30 and 32, respectively, to fully capture and enclose content within mailable content carrier device 10.

[0031] Important to note, content placement occurs during construction of device 10. Such placement of content on the upward-facing surface of panel 20 is well adapted for high-speed automation, i.e., placement of content on panel 20 prior to folding over tab panels 70 and 72 and subsequent folding of tab panels 70 and 72 can be fully automated by high-speed item placement equipment. Content placement under the present invention can be distinguished relative to content insertion as found in some prior art methods. Content insertion into a previously constructed mailable carrier, i.e., by inserting content between face-to-face panels of a paper structure, requires more complicated and relatively slower speed equipment, if not actual hand manipulation, to suitably locate, i.e., insert, content. Under the present invention, however, content placement during construction of the mailable content carrier device 10 supports fully automated and high-speed production.

[0032] FIGS. 3-7 illustrate concurrent construction of device 10 and placement of content therein. In FIGS. 3-7 blank 10′ moves as illustrated at reference numeral 100 through conventional folding and content placement equipment (not shown) along a path parallel to its lateral axis 42. FIG. 3 illustrates blank 10′ in perspective prior to entry into automated folding equipment.

[0033] In FIG. 4, gate folds along fold lines 30 and 32 bring panels 12 and 20, respectively, into face-to-face relation with panels 14 and 18, respectively.

[0034] In FIG. 5, content 102 is placed by automation on the upward-facing surface of panel 20 intermediate of tab panels 70 and 72.

[0035] Right angle gate folds along lines 74 and 74 bring tab panels 70 and 72 over and onto content 102 as seen in FIG. 6. Also in FIG. 6, glue is applied by automation to the upper-facing surfaces of tab panels 70 and 72 and also to the upper-facing surface of length portion 20 b of panel 20. A gate fold along lines 34 and 36 brings tongue panel 12 against the glue bearing portions of panels 70, 72, and 20 thereby securing together the overall structure of device 10 including secure containment and enclosure of content 102 therein. Thus, panels 12, 20, 70, 72, and 16 form a containment pocket enclosing and securing content 102 within mailable content carrier device 10. As explained more fully hereafter, this containment pocket opens upon removal of panel 16 and presents content 102 for convenient removal by the end user.

[0036] The above-described blank 10′ and method of manufacture can be successfully implemented according to a broad variety of machines and manufacturing methods. It has been successfully implemented by use of a folder-gluer machine with a pick and place machine integrally coupled thereto for placement of content 102 during the folding and gluing process as described above. It will be understood, however, that the present invention shall not be limited to any particular machine or machine configuration.

[0037] At this point device 10 has been constructed with content 102 suitably enclosed therein for submission to a mail carrier service. An additional step would include automated high-speed placement of address and postage indicia thereon. Device 10 thereby assumes by high-speed automated process the generally flat overall configuration holding content 102 securely therein and suitable for submission to a mail carrier service.

[0038]FIGS. 8 and 9 illustrate deployment of content 102 by an end user, i.e., recipient, of mailable content carrier device 10. In FIG. 8, device 10 is shown in its fully deployed position with content 102 and panels 12, 20, 70, and 72 vertically disposed. FIG. 8 illustrates in phantom panels 14 and 18 at an intermediate position during deployment. FIG. 9 illustrates mailable content carrier device 10 in its fully deployed position as seen along lines 9-9 of FIG. 8. In FIGS. 8 and 9, device 10 begins in a vertical orientation with its top presented as center panel 16 and its bottom resting against a supporting surface (not shown), i.e., a position similar in orientation to that illustrated in FIG. 1. The end user pinches the upper and outer-facing surfaces of panels 14 and 18 in the vicinity of center panel 16 and applies downward pressure.

[0039] As device 10 bears against the supporting surface (not shown) therebelow, panels 12 and 20, and possibly content 102 depending on relative size and stiffness, bear against the inner surface of center panel 16. This causes detachment of center panel 16 thereby opening a portal throughwhich content 102 and panels 12, 20, 70, and 72 pass. Panels 18 and 14 fold under the downward pressure along lines 50 a-50 b and 60 a-60 b, respectively. More particularly, sub-panels 14 a and 14 b detach at cut line 52 and remain attached at fold lines 50 a and 50 b. Similarly, sub-panels 18 a and 18 b detach at cut line 62 and remain attached at fold lines 60 a and 60 b. As previously mentioned, cut line 52 may be omitted by extending fold lines 50 a and 50 b together. Cut line 62 may be omitted by extending fold lines 60 a and 60 b together. As downward pressure continues, sub-panels 14 a and 18 a reach a horizontal position as illustrated in FIGS. 8 and 9 while sub-panels 14 b and 18 b extend diagonally upward from fold lines 50 a-50 b and 60 a-60 b, respectively, to support in vertical orientation the assembly of content 102 as held in place by panels 12, 20, 70, 72. Upon reaching this final position, length portions 12 c and 20 c of panels 12 and 20, respectively, engage the ends of the opening or content portal left by center panel 16 thereby securing the overall structure in the configuration as illustrated in FIGS. 8 and 9.

[0040] The user then plucks content 102 from device 10 by grasping and pulling upward on the upper exposed edge of content 102, i.e. as exposed at upper edges of panels 12 and 20. As best seen in FIG. 2, the edges 12 d and 20 d of panels 12 and 20, respectively, are cut along a concave path to better expose the upper edge of content 102 when deployed for removal as illustrated in FIGS. 8 and 9. Thus, the containment pocket formed by panels 12, 20, 70, 72, and 16 opens upon removal of panel 16 and presents content 102 for convenient removal by the end user.

[0041]FIG. 10 illustrates an overall bulk mailing operation including processing an inventory of blanks 10′ of FIG. 2 and content 102 carried thereby into mailable content carrier devices 10 of FIG. 1 for submission to a mail carrier service and ultimately distributed to a population of end users. In FIG. 10, blanks 10′ constitute infeed or source material to folding and gluing machine 120. A pick and place machine 122 receives as infeed content 102. Pick and place machine 122 integrally couples to machine 120 to place content 102 appropriately, e.g., as described above on content site panel 20, during the folding and gluing operation performed by machine 120. Machine 120 thereby provides as output mailable content carrier devices 10 to an addressing station 124. Station 124 references a database of addresses for end users and applies address and postage indicia 130. Thus, station 124 provides as output mailable content carriers 10″ each holding securely a content 102 item and bearing the necessary address and postage indicia for submission to a mail carrier service 140. Mail carrier service 140 then distributes mailable content carriers 10″ to individual members of a population of end users 150.

[0042] Thus, an improved mailable content carrier has been shown and described including adaptation for high-speed processing during construction and placement of content therein.

[0043] It will be appreciated that the present invention is not restricted to the particular embodiment that has been described and illustrated, and that variations may be made therein without departing from the scope of the invention as found in the appended claims and equivalents thereof. 

What is claimed is:
 1. A mailable content carrier blank comprising: first, second, third, fourth, and fifth panels, said first and second panels adjoining along a first lateral fold line, said second and fourth panels adjoining along collinear second and third lateral fold lines, said fourth and fifth panels adjoining along a fourth lateral fold line, said third panel being removably attached to said second and fourth panels; and sixth and seventh panels attached to first and second longitudinal edges of said fifth panel along first and second, respectively, longitudinal fold lines.
 2. A blank according to claim 1 wherein said first lateral fold line extends laterally across a lateral dimension of said first and second panels.
 3. A blank according to claim 1 wherein said second and third lateral fold lines extend partially across a lateral dimension of said second and fourth panels.
 4. A blank according to claim 3 wherein said second and third lateral fold lines terminate at said third panel interposed therebetween.
 5. A blank according to claim 1 wherein said second panel comprises first and second sub-panels and said fourth panel comprises third and fourth sub-panels, said first and second sub-panels adjoining along a first at least one lateral fold line, said third and fourth sub-panels adjoining along a second at least one lateral fold line.
 6. A blank according to claim 5 wherein said first at least one lateral fold line comprises two collinear fold lines interconnected by a curvilinear cutout line.
 7. A blank according to claim 5 wherein said second at least one lateral fold line comprises two collinear fold lines interconnected by a curvilinear cutout line.
 8. A blank according to claim 1 wherein said third panel is surrounded by circumferential cutout line.
 9. A blank according to claim 1 wherein a lateral dimension of said third panel is greater than a lateral dimension of a length portion of at least one of said first and fifth panels.
 10. A blank according to claim 1 wherein a lateral dimension of said third panel is greater than a lateral dimension of a length portion of each of said first and fifth panels.
 11. A method of constructing a mailable content carrier device comprising the steps: providing a carrier blank having first, second, third, fourth, and fifth panels, said first and second panels adjoining along a first lateral fold line, said second and fourth panels adjoining along collinear second and third lateral fold lines, said fourth and fifth panels adjoining along a fourth lateral fold line, said third panel being removably attached to said second and fourth panels, said blank further having sixth and seventh panels attached to first and second longitudinal edges of said fifth panel along first and second, respectively, longitudinal fold lines; folding said fifth panel along said fourth lateral fold line into face-to-face relation with said fourth panel; placing content on an exposed surface of said fifth panel; folding said sixth and seventh panels along said first and second longitudinal fold lines onto said content; applying glue to exposed surfaces of said sixth and seventh panels and to an exposed surface of said fifth panel; folding said first panel along said first lateral fold line into face-to-face relation with said second panel; and folding a first assembly including said first and second panels along said second and third lateral fold lines into face-to-face relation with a second assembly including said fourth, fifth, sixth, and seventh panels.
 12. A method of constructing a mailable content carrier device comprising the steps: folding content into a structure including a removably attached panel; and allowing relative sliding movement of said structure between said content and said removably attached panel whereby such sliding movement detaches said removably attached panel, passes said content through an opening left thereby, and exposes said content for removal by an end user. 